Unitized building structure utilizing precase components

ABSTRACT

A unitized building and a method of mass-producing the same that features the use of percast wall and floor components with the wall components being provided with vertical voids that are in registry with the spacing between adjacent horizontal floor sections which are, in turn, supported on said wall sections in spanning relationship thereto. The floor components are precast prior to delivery to the site so that upon in situ pouring of the floor slabs to proper thickness, the cement being used is forced into the voids of the wall panels to effectuate a concrete fusion between wall and floor components.

[451 May 16, 1972 [54] UNITIZED BUILDING STRUCTURE UTILIZING PRECASE COMPONENTS [72] Inventor: Thomas J. Dillon, 692 Woodbrook Rd.,

Cuyahoga Falls, Ohio 44223 [22] Filed: Jan. 12,1970

[21] Appl.No.: 2,177

[52] US. Cl ..52/251, 52/262, 52/272 [51] Int. Cl. ..E04b 1/16, E04b 5/16 [58] Field of Search ..52/250, 251, 259, 260, 319-324, 52/602, 253, 263, 262, 258, 261, 262, 272

[56] References Cited UNITED STATES PATENTS 749,812 1/1904 Buente ..52/324 791,875 6/1905 Buente ..52/250 872,111 11/1907 Dow 1,863,981 6/1932 Groves 2,294,554 9/1942 3,533,204 10/1970 Wallace et al. ..52/250 3,538,654 1l/l970 Gerola ..52/259 FOREIGN PATENTS OR APPLICATlONS 624,976 1963 Belgium ..52/262 39,809 1957 Poland .52/2 72 Primary Etaminer-Frank L. Abbott Assistant Examiner-James L. Ridgill. Jr. Attorne vFreeman & Taylor [5 7] ABSTRACT A unitized building and a method of mass-producing the same that features the use of percast wall and floor components with the wall components being provided with vertical voids that are in registry with the spacing between adjacent horizontal floor sections which are, in turn, supported on said wall sections in spanning relationship thereto. The floor components are precast prior to delivery to the site so that upon in situ pouring of the floor slabs to proper thickness, the cement being used is forced into the voids of the wall panels to effectuate a concrete fusion between wall and floor components.

3 Claims, 6 Drawing Figures PATENTEDMAY 16 I972 3,662 506 SHEET 1 OF 2 l THOMAS J. DILLON 20 40 BY J/ mk v I ATTORNEYS PATENTEDMAY 1s 1972 SHEET 2 [1F 2 INVEN'I'OR. THOMAS J. DILLON I Z I 55:] T

BY f/uum.

FIG.5

ATTORNEYS UNITIZED BUILDING STRUCTURE UTILIZING PRECASE COMPONENTS BACKGROUND OF THE INVENTION DESCRIPTION OF THE PRIOR ART High-rise construction of the type herein being discussed has long been known in the building construction industry. In the past, various methods and approaches have been taken to this subject with the type of construction that has been and is being employed varying considerably.

Because of rising wage and labor costs in the construction industry, recent attempts have been directed to preforming as many of the components as possible at factory locations so that the same can be then erected at the site with minimal use of skilled artisans, such as brick-layers, etc.

In this regard, it is known at the present time that floor panels can be precast. However, at the present time weight and space requirements have limited the degree to which precast components can be employed. Weight in this regard is not only important from a shipping standpoint but is important from the standpoint of the ease of erection and handling that is involved at the building site.

Thus it becomes axiomatic that while the use of precast components is desirable, it is mandatory that such components be capable of being supported and erected without unusual effort and expensive equipment being required.

To this end, construction techniques at the present time presently include the pouring or laying up of the vertical walls at the site. The walls then receive precast floor components that are only partially poured as regards thickness. Once these slabs are positioned in place at the site, the remaining portion of the slab is poured so that the finished product is completed.

While the above technique has resulted in a technical advance, there still remains the difficulty of fusing the floors to vertical wall components, and also there is an inability, in the known art, to erect several stories before pouring.

SUMMARY OF THE INVENTION It has been discovered that all essential components of the building can be precast prior to delivery to the building site and then assembled in situ followed by pouring in a fashion that in effect fuses' the wall and floor components together.

In this regard, the conventional wall panel is cast with a series of vertical voids therein, with the voids serving the dual purpose of lightening the precast components for shipping and erection purposes, while simutaneously providing recesses within which the finishing concrete used at the building site can be received so as in effect create a fusion between the wall and floor components following final pouring at the site.

It has further been discovered that if the wall component is provided with appropriate horizontal undercuts on its lower edge communicating with the vertical voids, that several floors can be erected efficiently prior to anypouring.

These undercuts straddle the longitudinal ribs of the floor panels so that as the finishing pour is taking place, cement can pass through the void provided by these undercuts and thus into the vertical voids that are connected thereto. By this arrangement the finishing concrete not only cover the surface of the floor slab to the desired thickness, but is also received within the vertical voids of the wall panel so that wall panel and floor panel are bonded or fused together by the same finishing concrete.

It is also contemplated that auxiliary mechanical fastening can be employed between the components just described so as to insure rigidity prior to the time of final pour. This auxiliary fastening takes the form of angled rods which carried by the floor components and can be tack welded to appropriate plates on the walls to prevent shifting between the floor and walls as well as serving as reinforcing members after the finish concrete has been poured.

Attainment of a building technique achieving the above described objectives accordingly becomes the principal object of this invention with other objects thereof becoming more apparent upon the reading of the following brief specification considered and interpreted in view of the accompanying drawings.

OF THE DRAWINGS:

FIG. 1 is a perspective view partly broken away and in fact, and illustrating improved building construction method apparatus.

FIG. 2 is a plan view showing floor slabs in place on a vertical wall section.

FIGS. 3, 4, and 5, are sectional views taken on the lines 3- 3, 44, and 4-5 of FIG. 2.

FIG. 6 is a vertical section taken on the line 6-6 of FIG. 3.

7 DESCRIPTION OF THE PREFERRED EMBODIMENT lar in elevational view and includes a top edge surface 11, bottom surface 12, and opposed planar faces 13 and 14. In accordance with known building techniques the lengthof the panel 10 will be an even multiple of the width of the floor slabs 20,20 so that a given number of floor slabs will be supported in flush relationship to the top surface of an individual wall panel 10. In practice it is contemplated that the wall panel 10 will be approximately 24 feet long by 8 feet high by 6 to 10 inches thick so as to support six 4-foot wide panels that can vary in length as desired. It should be understood however that the invention is not intended to be limited to any specific dimensions and the particular figures cited are for illustration only.

Also and referring to FIGS. 1, 2, 3 and 4, the wall panels 10 have a plurality of vertical voids 15,15 that are shown spaced equi-distant between the opposed planar faces 13 and 14, and that extend between the top surface 11 and the bottom surface 12 of the panel. As pointed out earlier, the purpose of these voids 15,15 is twofold in that their presence first, materially reduces the weight of the panel in question, andthat, secondly, these voids 15, 15 are subsequently filled with concrete during the final pouring operations so as to effectuate fusion or bonding between the floor and wall panels following erection.

The preferred embodiment of the invention shown herein also contemplates erection of additional stories prior to the finish pouring of the particular floor being built. In this fashion, for example, the crew erecting the wall panels and laying in the floor slabs can stay two or three stories ahead of the crew pouring the concrete.

Accordingly, a series of transverse, horizontal grooves 16, 16 and 16a, 16a are provided in the bottom surface 12 of the wall panel 10, with these grooves extending transversely on the wall 10 between the planar surfaces 13 and 14. In the preferred embodiment shown, the grooves 16,16 are shown having a greater depth than the grooves 160, 16a, with this arrangement being illustrated best in the lower portion of FIG. 1. It is to be noted that the grooves 16,16 and 16a, 16a correspond in total number to the number of voids 15,15, and further that these grooves are in vertical alignment with such voids in all instances.

Again referring to FIG. 1, the floor slabs 20,20 are, as previously indicated, identical in construction. These panels are pre-cast to a rectangular configuration so as to include a base portion 20a, a longitudinal edge portion 21, anda series of up-.

wardly projecting ribs 22,22 and 22a, 22a. The ribs 22 extend throughout the longitudinal extent of slab 20 so as to have their ends flush with the longitudinal end 21 of the slab, as clearly shown in FIG. 1 of the drawings. The ribs 22a, 22a, on the other hand, terminate short of the edge 21 for purposes that will be subsequently described. Additionally, conventional reinforcing rods 40,40 are shown extending longitudinallyof floor panel 20 for known purposes of reinforcing.

With reference to the method of connecting the floor panels on the wall panels as preliminary to the final pouring operation, it is believed apparent that several alternatives are available.

First, the units could be provided with tack pleats 41,41 and 42,42, which could be welded together on site. Alternatively, a series of right angle rods 43,43 could be placed loosely in position, as shown in FIG. 1, with the weight of the members holding the same in place until such time as pouring operations could be completed, at which time the members 43,43 would serve as reinforcing units.

Finally, and in the event it is desired to build several stories ahead and rigidity is required, a more rigid type of connection could be used by employing welding components mechani cally interlocked the floor and wall panels together.

In this regard, and referring now to FIGS. 3 and 4, it will be seen that the ribs 22,22 are provided with metal plates 23,23 that are spaced inwardly from the outward ends of the slab, two inserts being provided on each rib, as shown best in FIG.

These inserts 23,23 serve as the point of attachment for certain connecting elements 24, 25, 26 and 27, which will now be described. In this regard, the elements 24 and 25 are right angle metal rod components that respectively push against and pull against opposed wall portions of the void 15, as best shown in FIG. 3. By this arrangement, the slab 20 is locked in place against longitudinal shifting with respect to the wall 10, once the components have been fastened in place, as shown in FIG. 3 as by the use of tack weld applied to the metal plate members 23,23. In this regard, it is apparent that the plate members 23,23 may be cast in place or may be attached as by the use of bolts or other fastening means. The rods 26,27 are straight in profile and are intended to project coextensively from one edge of slab 20 to connect with the adjacent coextensive rod for attachment and alignment purposes. Such attachment then precludes vertical or transverse shifting of the floor slabs.

Once the floor slabs have been completely assembled as shown in the upper portion of FIG. 1, it is believed apparent that another wall panel can be positioned on the floor slabs 20,20 so as to start construction of another floor. In this regard, the ribs 22,22 and rods 24, 25, 26 and 27 will all be received within the void created by the groove 16 so that the bottom surface 12 can be freely received on the upper edge portions of the slabs 20,20, with this condition being illustrated in the lower portion of FIG. 1 of the drawings. While the rigs 22,22 are received within the grooves 16,16 as just described, the ribs 22a,22a are designed so as to be in flush abutment with the planar faces 13 and 14 once the panel is positioned in place. Further positioning, in effect, is achieved by the use of centering pins 31,31 provided in the top and bottom surfaces 11 and 12 of the wall panel 10. Thus, the pins 31, 31 preclude longitudinal or transverse shifting of the unit while the flush abutment of the ribs 22a,22a with the opposed sides of the wall panel provides further support against transverse shifting.

In this regard, the pin employed is preferably a tapered pin that is received within a tapered pipe 32 that extends vertically and opens into the surfaces 11 and 12 of the wall panel 10. The pin and pipe which are illustrated are relatively short but they can be extended to any desired length to give further stability to the structure prior to the final pour if desired.

When a wall panel 10 has been assembled on positioned floor panels, as shown in the bottom portion of FIG. 1, it is merely necessary that the concrete be poured to the level indicated by the line L in FIG. 1 of the drawings. During such pouring, the concrete will pass through the grooves 16,16 and l6a,l6a, and thence into the vertical voids 15,15, with gravity insuring that the voids 15,15 will be completely filled so that a unitization or fusing of the members together is insured by such pouring operation.

it is believed apparent, however, that prior to such pouring, it would be very simple to install the utility conduits or openings on top of the positioned slabs 20,20 with it being intended and contemplated that all electrical and other outlets would be positioned in place prior to completing the final pour.

In this regard, it will be noted that the finished floor line indicated by the line L" is above the uppermost surface of the grooves 16,16 and 16a,16a, so that when final pour is completed, no trace will remain of the grooves 16,16 and 16a,l6a, which will have been covered up during such pour. Additionally, and once the floor and wall components have been assembled as just described, it is believed apparent that corridor walls and other internal walls could be readily positioned, using known techniques.

With reference to the pouring operations just mentioned, it is believed apparent that several alternatives are also available here, dependent upon strength requirements. For example, while a solid pour of concrete may be required adjacent the point of connection with the wall panel, it is apparent that the intermediate portion of the floor panels could be provided with voids that would be created as by laying a plate or wire mesh over the upper surfaces of the ribs. Additionally, a honey-combing arrangement could be employed in this regard if necessary.

It should be noted that where several floors are to be erected before final pouring some additional reinforcement may be desired. In that case it would be possible to position the corridor walls, which run perpendicular to wall panels 10,10, before installing the next floor slab 20. Also X-bracing or some similar means of increasing stability may be employed if desired.

On the other hand if each floor is to receive the final pour before adding the next, the saw-tooth bottom edge of panels 10,10 may be eliminated by eliminating grooves 16,16 and l6a,16a. In this method one series of wall panels is erected on the conventional foundation (not shown) and the floor slabs 20,20 are placed in position. The final pour of concrete is then accomplished so that a unitary continuous structure is created. The second series of wall panels are then erected and the process can be repeated for the second floor.

While a full and complete description of the invention has been set forth in accordance with the dictates of the Patent Statutes, it is to be understood that the invention is not intended to be limited to the specific form herein shown. Accordingly, modifications of the invention may be resorted to without departing from the spirit hereof or the scope of the appended claims.

What is claimed is:

l. A modular building for use on a prepared foundation site of the character described, comprising;

A. a plurality of precast unitary reinforced concrete wall panels l. at least two of which are arranged in parallel, spaced alignment with each other 2. each having at least one vertical void centrally thereof that extends from top to bottom;

B. a plurality of elongated solid precast floor panels 1. having the lower surface of the opposed end portions thereof resting on the top of said spaced wall panels in non-covering relationship to said voids and forming a preliminary structure;

C. field-positioned reinforcing means 1. at least some component portions of which are a. received on top of said floor panels b. received within the voids of said wall panels;

D. site-poured concrete simultaneously the presence of interlocking means that prevent transverse and longitudinal shifting between adjacent horizontal surfaces of vertically adjacent wall panels.

3. The building structure of claim 9 further characterized by the fact that said precast floor panels and said precast wall panels each have elongate reinforcing rods embedded therein; said embedded reinforcing rods coacting with the reinforcing means embedded in said site-poured concrete to enhance the overall structural characteristics of the monolithic structure.

3,662,506 May 16, 1972 Patent No. Dated Thomas J. Dillon Inventor(s) It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Claims 2 and 3, line 1, claim reference numeral "9", each occurrence,' should read l Signed and sealed this 26th day of March 1974.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. C. MARSHALL DANN Attesting Officer Commissioner of Patents PC4050 (10-69) uscoMM-Dc 60376-P69 [LSJGOVERNMENT PRINTING OFFICE Z 959 '-365-33,

UNITED STATES PATENT oTTTQE QERMMQAEE QT QGRREQTEGN Patent No. 36625O6 Dated y 97 Thomas J. Dillon Inventor-(s) It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

On the cover sheet [54} in the title, the word "Precase" should read Precast in the heading to the specification, column 1, "P1980836" should read Precast Signed and sealed this 19th day of December 1972o (SEAL) fittest:

EDWARD mFLETctmmJfi. Attesting Officer ROBERT GOTTSCHALK Commissioner of Patents USCOMM-DC 60376-P69 1 u.s. GOVERNMENT PRINTING OFFICE: I969 0-366-334,

FORM PO-IOSO (10-69) 

1. A modular building for use on a prepared foundation site of the character described, comprising; A. a plurality of precast unitary reinforced concrete wall panels
 1. at least two of which are arranged in parallel, spaced alignment with each other
 2. each having at least one vertical void centrally thereof that extends from top to bottom; B. a plurality of elongated solid precast floor panels
 1. having the lower surface of the opposed end portions thereof resting on the top of said spaced wall panels in non-covering relationship to said voids and forming a preliminary structure; C. field-positioned reinforcing means
 1. at least some component portions of which are a. received on top of said floor panels b. received within the voids of said wall panels; D. site-poured concrete simultaneously
 1. filling said voids of said vertical wall panels
 2. completely enveloping said reinforcing means
 3. forming a floor surface on top of said wall panels
 4. integrating said temporary structure into a monolithic modular building structure defined by composite wall panels that are structurally connected to composite floor panels through the medium of reinforcing means that are integrally embedded in said site-poured concrete.
 2. each having at least one vertical void centrally thereof that extends from top to bottom; B. a plurality of elongated solid precast floor panels
 2. completely enveloping said reinforcing means
 2. The building structure of claim 9 further characterized by the presence of interlocking means that prevent transverse and longitudinal shifting between adjacent horizontal surfaces of vertically adjacent wall panels.
 3. The building structure of claim 9 further characterized by the fact that said precast floor panels and said precast wall panels each have elongate reinforcing rods embedded therein; said embedded reinforcing rods coacting with the reinforcing means embedded in said site-poured concrete to enhance the overall structural characteristics of the monolithic structure.
 3. forming a floor surface on top of said wall panels
 4. integrating said temporary structure into a monolithic modular building structure defined by composite wall panels that are structurally connected to composite floor panels through the medium of reinforcing means that are integrally embedded in said site-poured concrete. 